Method of producing an article of manufacture



April 18, 1933. H. L. cRowLl-:Y

METHOD 0F PRODUCING AN ARTICLE 0F HANUFACTURE Filed Jan. 14, 1929Patented Apr. 18, 1933l 's UNiTED sTATss I HENRY L. caowmx, or naaronarrein,l Naw man, Assmann 'ro maar.. a oo 1Nc or naar omen, maw unan,a conroa'a'rxon or maw man! METHOD 0l' PRODUCIN G AN ARTICLE 0IHANUIACTUBI Application illed January 14, 1929. Serial lo. 388,555.

This invention relates to new composition of matter and to the method ofproducing the same.

The object of the invention is to provide a new composition of matterand the method of producing the com ition, it having practicallyunlimited utility and the method permitting predetermination of physicalcharacteristics of the product within wide limits.

Therefore, the invention consists of a new substance (and variationsthereof rmitted within the scientific laws) as we as the method ofproducing this new substance, irrespective of the specilic use to whichthe new substance may be put, as will be hereinafter pointed out. Theparticular requirements of any particular product determine to a largeextent, the ingredients of the new substance.

The periodic table of Mendelejel is now universally recognized asdefinitely establishing certain relations and lack of relations betweenthe various elements of the universe. Using the periodic table as astarting point I have discovered that a law may be formulated basedthereon and applicable to a portion, at least, of the periodic table.This discovery is of great scientific significance and from it greatpractical commercial benefits may be derived. While my investigationshave not been carried on to an extent which warrants a statement at thistime based on exhaustive, conclusive work that the law is universallyapplicable to the periodic table, nevertheless, they have been completedto a point where it can be conclusively stated'that the new law isdeinitel applicable tocertain portions of the periodic table andparticularly to the portions that pertain t0 tween delinite parallellines diagonally.'

drawn on a charted periodic table have sim- .ilar physicalcharacteristics.

tions have established that My investi this law whic for want of abetter name, mayabe termed the diagonal law of the periodlc table, isstrictl a plicable to the o xides of the metals. IVhie my investigationsthus far have not conclusively established tlie fact theystronglyfiindicate that the law ,is applicable toall metals, in allchemical com inations which have the similar physical characteristic `ofbeing obtained or obtainable in powdered form. In other words, ancomposition having a metal as its base whic can be produced in apowderedor pulverized form, such as the pure metal itself or its oxides,ycarbonates, sulphates, carbides, etc. appare `tl obey the diagonal lawof the periodic ib e Inasmuch as my investigations have not been carriedto the point where I can conclusively assert 4that the diagonal law isapplicable to all powders of a metallic base, although the indication isstrongly to that effect, the present disclosure will be illustrated byoxides of the metals, as to which my investigations have been completedand conclusive results obtained. The diagonal law thus confined may bestated to be that the oxides of metals lyinv between definite paralleldiagonal lines of tlzie charted periodic table-have physicalcharacteristics. The drawing `illustrates a` charted table showin themanner of grouping the metallic salts 1n diagonal roups.

The law thus stated and established as to its correctness obviouslyopens entirely new fields of investigation with limitless practical,commercial, scientific value, and utility. It would be, perhaps,impossible for any one similar specific line of investigation thusopenedup the necessity for radical improvement therein, has presented amost attractive field for immediate investigation.. For this reason,althou h I do not desire to be limited or restricte thereto I haveselected the applica'- here disclosed and broadly claimed in theappended claims.

. The oxides of all metals come under two heads,('1) conductors, and (2)non-conductors. The-conductors va widely lin their resistance to' theiow o electric current therethrough. I have found accordin to theperiodic table that there is a Well de ed line of division between theoxides of metals that are conductors and the oxides of metals that arenon-conductors, which line of division is a diagonalline on the chartedperiodic table and apparently depends on the series-group relationshipbetween the metals themselves and the atomic weight of the oxides of themetals. By means of this diagonal line of division, one finds theperfect insulators, such as magnesium oxide, zircon, beryllium, etc.Further on the insulator side of the dividing line one linds inaccordance with the diagonal law, the electroactive metals, i. e.,emitters, such( as thoria, strontium oxide, barium oxide, etc.

Still further on the insulator side of the line, one finds in accordance"with the diagonal law, radioactive materials, such as uranium oxide,radium oxide, etc.

On the opposite side of the dividing line, one finds in accordance withthe dia onal law high resistance conductors, suc

and convenience of procurement, I have been able to produce productshavin any desired and predetermined electrical c aracteristics in so faras conductivity, insulation or resistance is concerned.

In other words taking for example, the necessity or desirability ofproducing in commercial quantities conductor elements of predeterminedor fixed resistance, it is well recognizedthat this is one of the manyproblems in the' electrical art that has remained unsolved. While theresistance element may be produced and its resistance care- ;fullymeasured, it has been-practically impossible to produce thatv,resistance in commercial quantities without a wide variation inelectrical characteristics between the supposedly identical products.This has seriously hampered manufacturers in the electrical art,necessitatingv the design of equipment which permits a comparativelywide variation in resistance to meet the inability of the manufacturersto produce in commercial quantities, at low cost, resistance eleaschromium oxide, manganese oxide, etc. Still a l ments of 'predeterminedresistance characteristics. lems of the electrical art is solved by thediscovery of the diagonal law and the method of practical utilizationthereof.

With the diagonal law lixed, the problem next presented consistedl ofthe procedure, treatment or processing of the powdered metal oxide toenable the practical utilization thereof. Iwill now describe the processemployed to produce an ultimate product of an entirely new compositionof matter having the predetermined electrical and physicalcharacteristics. l

The rst determining factor in the production of any ultimate product, inaccord-l ance with my invention consists of the use to which theultimate product is to be put. If the ultimate product is for insulationproperties, the oxide or oxides of a metal or metals complying with thediagonal law in the insulation area between the diagonal lines isemployed. If a conductor is desired, the oxide or oxidesof a metal ormetals complying with the diagonal law lying This, as well as many otherprob-x i in the area/between the diagonal lines on the conductor side isemployed. If mixed properties are desired the oxides of mixed metals areemployed. Therefore, theoxide or oxides of any desired metal or anymixtures `of oxides of metals (depending on the factors of manufacture,such as ultimate use, desired properties, cost, etc.) is obtained in apowdered form, either in the raw state or additionally pulverized, so asto reduce it to powdered form.y The'powder thus obtained is next fired,i. e. subjected to heat treatment to drive out moisture and impurities.The details of this initial firing form the subject matter of a separateinvention for which separate application will be made. It

is sui'licient to here state that I` have jdising upon the ultimate useto which the product is to be put). When a mixture of powders is used,depending upon the factors -hereinbefore set forth, the next stepcomprises at this stage thoroughly mixing the powders. This may beaccomplished in any suitable way. Mechanical mixers well known, parlticularly in the ceramic art, are suitable for this purpose. The dried,purified powder then has added to it a removable binder, i. e. somematerial of a pure character (so as not to add impurities t0 themixture) and of a nature that can be easily removed from the productbefore completion. I ind a liquid -tion of the material.

solution of gum arabic suitable for this pur-`l pose, inasmuch as puritycan be maintained and firing can lnsure the burning out thereyof-fromthe ultimate product.

, it is possible `to produce rods of any desirable diameter and length,having any external configuration. Similarly, hollow cylinders`or othershapes may be obtained. i.

Likewise, one or more longitudinally extending oriiices, of any desireddiameter down to and including the hair-like diameter of a radio vacuumtube filament, may

be obtained. The external and internal surfaces of the extrudedproductsscan be rough or smooth as desired. In fact all the physicaicharacteristics'incident to extrusion can be secured.

The extruded product consists solely of powdered metallic oxide (plusthe binder, ii used, which is iater eliminated), the particles of whichhave been subjected to su@- cent compression, so as to create cohesiontherebetween, and the product, while stiil capable of being broken u"into its powdered form, nevertheless has su icient strength and sierigidity to permit being handied and machined. It can have holes boredtherethrough; it can be sharply cut away without chipping its edges; itcan be turned on a lathe, and, inL generai, subjected to any and allforms of linachiiiing which do not invoiye excessive pressure orstrain..

rIhe product aiter being machined in. accorriance with its ultimate use,and the desired shape, etc., is nally baked. The speciiic details oi thebaiting o3 the product thus fai* obtained `forms the subject mattei. ofa separate application 4or a patent therefore the details thereof neednot be here given. lint-he present case it is suiiicient to state thatingenerai the intermediate product thus obtained is subjected to heat inoyen for a period of time and. at a temp 'ture depending upon theparticuiar metaiiic oxide or mixture thereof, and the uitimate use tewhich product is to be put. The time of the b is not particulariycriticai.

Likewise the heat baking (which iiiiew wise is a in determining theiength of time oi? lashing) may be varied within` wide iimts. .is arule, however, and except in eaceptionai circumstances the bakingtemperature should not exceed the fusing pbint of the metallic oxideemployed. When the product ,thus obtained is taken from the oven .andcooled, its physical .characteristics (other than size and shape, exceptfor shrinkage in some instances) have been altered completely. lA hard,strong, light,nonbritt1e, nonductile structure with high tensilestrength is obtained. Its conductivity7 and insulation properties arecontrolled entirely by the powdered ingredients thereof. It ispractically non-breakable and-is harder than glass, tool steel, etc. Itis a resistant to heat, has a negligible coeilicient of thermalexpansion, resists chemical reaction, is non-corrosive and is smooth,porous or non-porous as desired, The product obtained in accordance withmy invention has utility inu practically #all of the arts. In theelectrical arts its utility as nan insulator, resistor, conductor,emitter, spark plug, etc. will be readily apparent. Due to itsresistanceto hi h heat it is useful for oil burning parts, spar plugs,pyrometer tubes, etc. Its extreme hardness makes it available for use asscale bearings, etc. Indeed, the utility of the product is as broad asthe arts and sciences. No product of this character has ever to myknowledge been heretofore produced.

As hereinbefore mentioned by employing ingredients selected inaccordance with the use to which the ultimate product is to be 'putit ispossibie to provide practicaily inde structible ,insuiators resistors,conductors, emitters, etc. in the eiectrical arts and in fact a ynewcomposition which may be utilized in any art where a product or productscontaining the physical characteristics oi my product is desirable.,

it will he apparent that many modiiica-v tions and changes in theprocess o "producin the product will readily occur to those shiiled inthe without departing *from the spirit and scope oit my invention asoleiined in the ciaiins. It Wili likewise be apparent that the physicaicharacteristics of any particiilar product can be Varied vziil and Itherei'ore desire to have the foregoing ciescription re fa in theillitstrative and not and the process ci.2 producing the seme, what Iclaim as new and useful and oi my own invention and desire to secure byLet ters Patent is i. The method which consists in reducin a metai topowder, subjecting the powdere metal to a, heet below the fusion peintof the metal, then extruding the powfcer te solidify .the same and nallybaking the soidied mass.

5 2. The method of proxucing ein insulator bedy from' a powdered metaloxide which comprises subjectin the pewdered metal exide to heat Tbeow te fusion point itrieieofe extrudng ldie powdered metal oxide undef 1Gpressure to soiidiffy the same, and naiy heat treating the solidifiedmass.

Xn testimony whereof have hereunto set my hand en this Mish day ofJanuary A, D? 1929. l5 MERY L. CRVVLEY.

